CN102764847A - Precision forming method of straight/helical tooth cylindrical gear - Google Patents
Precision forming method of straight/helical tooth cylindrical gear Download PDFInfo
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- CN102764847A CN102764847A CN201210239825XA CN201210239825A CN102764847A CN 102764847 A CN102764847 A CN 102764847A CN 201210239825X A CN201210239825X A CN 201210239825XA CN 201210239825 A CN201210239825 A CN 201210239825A CN 102764847 A CN102764847 A CN 102764847A
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Abstract
The invention relates to a precise forming method of a straight/helical tooth cylindrical gear. The precise forming method disclosed by the invention is characterized by being realized by the following two steps while a 'diameter-increasing half long ridge-tooth space splitting' way is adopted: firstly, closed die forging is carried out on cylindrical blank to form a pre-formed part, wherein one end of the pre-formed part is larger in radial dimension, sectional area and edge axial dimension and the other end of the pre-formed part is equal to the required value of the sectional area and has slightly smaller radial dimension, the two ends transit in a bevel angle manner, and a cylindrical surface is in a 'diameter-increasing half long ridge' state; and secondly, the pre-formed parts penetrate through a final forming die each tooth space of which is correspondingly provided with a splitting wedge in a sequence from big end to small end, wherein a splitting edge and a working surface of the splitting wedge are in a tilted state, a rim is split, extruded and deforms, and each slot base is deepened and the top of each ridge is lifted, thus a gear tooth with complete tooth profile is obtained. The gear tooth/tooth space obtained by the invention is clear and full, a required forming force is relatively small, an equipment action is simple, a structure of a die is not complex, a workpiece is easy to demould, requirement to technological conditions is low, and adaptability is wide.
Description
Technical field
The invention belongs to metal forming technology field; Be mainly used in the machine components manufacturing; Relate to gear precision manufacturing process and mould thereof, be specially adapted to straight-tooth or the shaping of helical teeth cylindricality (cylinder or non-cylinder) gear precision that gear teeth cross sectional shape equates everywhere.
Background technology
Cylindricality gear (hereinafter to be referred as gear) is a kind of transmission power that has a large capacity and a wide range and the mechanical basic part of motion, generally is made up of wheel hub, spoke and toothed wheel rim, and internal gear then mainly is made up of toothed wheel rim.The by tooth traces shape is distinguished, and spur gear, helical gear, herringbone bear etc. are arranged.
Except straight-tooth thin slice (flange height is significantly less than radial dimension) gear can be by plate through stamping-out obtains; The conventional gears manufacture process is; Obtain the wheel blank that teeth groove fills up surplus through forging or casting earlier; Cut (insert/planing, milling, grinding etc.) is removed surplus and surplus then, obtains the gear teeth.For ease of cut with obtain better comprehensive performance and higher hardness, also need Technology for Heating Processing to cooperate in the manufacture process.
Stronger through forging the gear capacity that obtains, be the main flow that gear is made.There is following shortcoming in the tradition main stream approach: 1) forge and organize streamline to be cut off, reduced the mechanical property of the gear teeth; 2) cut takies number of devices and expends man-hour many, and the workpiece number of turnover is many, and the production cycle is long, and efficient is low; 3) stock utilization is low, and energy consumption is high, and manufacturing cost is high.
In order to overcome these shortcomings; Since generation nineteen sixty, people have carried out a large amount of fruitful research and discoveries with regard to gear (mainly being spur gear) precision form, still; The tooth axle less except that modulus, that radial dimension is less, gear precision is shaped and does not get into the commercial application stage yet.
Gear precision is shaped and also is called the gear finish forge, and the subject matter that needs to solve is gear teeth precision forms, directly obtains the complete gear teeth that the flank of tooth does not need or only need a little fine finishining to use through precision forging exactly.
Press the gear teeth/teeth groove shaping approach difference, existing gear (is example with the straight spur gear) gear teeth precision form mainly contains three types.In all kinds of shaping approach, the blank axis generally should with the die cavity dead in line, apply active force during shaping vertically.
The first kind is a grand full ridge approach.
Closed die forging is to be studied more thorough gear teeth accurate forming method.Generally select for use diameter to be slightly less than the cylinder blank of root circle, the gear teeth are all obtained by tooth root portion protuberance, so be called complete grand ridge approach.Complete grand ridge approach can be subdivided into one-step method and two-step method again.
(1) deformation process of one-step method is, blank is by axial upset, and inhomogeneous increase, loading mould cavity take place radial dimension.One-step method work step number is few, and device motion is simple, but lower end tooth (corner under the die cavity) is filled difficulty, even apply great active force, this position filling effect is still undesirable.Simultaneously, the mould service condition worsens, workpiece demoulding difficulty.Main cause is that this position die cavity relative width is little, and the metal flow stroke is long, need overcome four sides frictional resistance (all the other position frictional resistance less or be positive friction effect); If forge hot, metal flow can be lowered the temperature to this, mobile variation.One-step method is difficult to practical application.
(2) i.e. twice closed die forging of two-step method, deformation process are in same (or same) matrix cavity, earlier with preform punch upsetting pressure blank, to obtain the operation part; Use whole forming terrace die upsetting pressure operation part again, accomplish shaping.In advance, the difference of whole forming terrace die is embodied on the meridian plane, axis projection figure does not have difference.Two-step method can reduce plastic force, improves filling effect and mould service condition.But, the same matrix cavity of twice contact of wheel toothed portion of workpiece is unreasonable; The problem of workpiece demoulding difficulty still exists, and this is the grand entirely common shortcoming of ridge approach.
The method that also has twice closed die forging of a kind of employing two secondary moulds.The first step, by axial upset, obtain with the root circle is " Ban Longgeng " operation part (axially reserving necessary sized) of benchmark to blank in the concavo-convex amplitude of sidewall is a bit larger tham the half the preform die cavity of desired value; In second step, the operation part is placed in the whole shaping die cavity, axially by upsetting pressure once more; Suppose by means of " radial rigidity translation flow pattern "; Before expecting that promptly the gear teeth are full of, the contact pattern of die cavity sidewall does not contact with metal, eliminates or reduces the final shaping that external friction realizes the gear teeth.Do not fail to realize that because of being inconsistent corner is full of with law of minimum resistance.
The measure that improves complete grand ridge approach also has: floating cavity die shaping, closing mould forging, shunting shaping etc.These methods can be improved filling effect within the specific limits, reduce plastic force; But exist mould structure complicated, deficiencies such as equipment needed thereby action complicacy, practical application has received limitation.Wherein, shunting is shaped and also on workpiece, has added unnecessary volume, needs follow-up cut to remove, and both waste material had reduced production efficiency again, had offset the advantage of precision form on the certain degree.
In a word, there are many serious process limitation in grand full ridge approach.
Second type is standard-sized sheet groove approach.
Forward extrusion is that another kind is studied quite thorough gear teeth accurate forming method.Must diameter be approximated the metal that is positioned at tooth socket space on the cylinder blank of outside circle and all shift away, could obtain the gear teeth, so be called standard-sized sheet groove approach.
Forward extrusion can a step be accomplished gear-tooth forming, but the end face flatness of coming out earlier is poor, and the rear end need be left can not be through the step in mould type hole; Simultaneously, required plastic force is big, and blank and mould are long time of contact, and the mould service condition is abominable.It is generally acknowledged that forward extrusion is applicable to that the toothed major axis of cylindricality gear, particularly cylinder (comprising splined shaft) that radial dimension is less, modulus is less is shaped.This method has obtained the application of suitable scope.
Like publication number is that the one Chinese patent application " a kind of manufacturing process of straight spur gear " of CN1868633A belongs to this type.
The 3rd type is " open Long Geng-expansion groove " approach.
Since generation nineteen ninety, the gear teeth accurate forming method that a kind of being called " pushed away " is seen in report.What is called pushed away and was meant that punch promoted to place blank or middle operation part on the die to pass the die of band flank profil and is shaped, and the excision overlap behind its process and the conventional open die forging, impressing forging is similar.The method that " pushed away " has two types of one-step method and multistep processes.
(1) one-step method, promptly directly with diameter greater than reference circle, pushed away die less than the cylindrical blank (generally requiring the blank cross sectional area to equal the gear axial projective area) of outside circle.The die and the teeth groove corresponding position of adopting do not have the sword of splitting, and are unfavorable for that metal flows towards predetermined direction; The punch that adopts does not have profile of tooth, can not get into the whole shaped segment of die, needs a back workpiece to promote previous workpiece and could accomplish shaping.Research shows that for the gear teeth of big modulus, even sword is split in setting in the teeth groove corresponding position, in the deformation process, the notch of teeth groove protuberance is higher, and tooth top middle part protuberance is lower, and the result is confluxed folding in the formation of tooth top middle part; Simultaneously, the angle of collapsing, initiating terminal edge is serious.
Like publication number is that the one Chinese patent application " straight spur gear Extruding die " of CN1544175A belongs to this type.
(2) multistep processes promptly adopts earlier closed die forging " the open shaping " (root circle that refers to die is constant, and suitably relax in chamber, the tooth ridge), obtains the first operation part that tooth top is owed to be full of, the facewidth is more than needed; Pushed away shaping through several times again, and teeth groove was widened or the facewidth narrows down, tooth top raises.This method obtains the gear teeth through " open Long Geng-expansion groove " approach.
This method is minimum to be needed with 4 kinds of moulds, accomplishes through three big steps.The first step, warm attitude closed die forging (the monolateral amplification a of flank profil, a gets 0.8 ~ 6.0mm, profile of tooth area big approximately 5% ~ 40%); In second step, warm attitude pushed away shaping (the monolateral amplification b of flank profil, b gets 0.1 ~ 3.5mm, profile of tooth area big approximately 5% ~ 30%); In the 3rd step, cold conditions pushed away shaping (the monolateral amplification c of flank profil, c gets 0.0 ~ 2.5mm, profile of tooth area big approximately 0% ~ 20%).The monolateral amplification quantity a of flank profil＞b＞c.The deflection of each shaping step can not be excessive, and for the bigger gear of modulus, each step need use the mould of multilevel size to accomplish several times.In the shaping process, flange height no longer changes.
The deficiency that this approach exists is: 1) " open and be shaped " intensity that has weakened with teeth groove corresponding position die and demoulding difficulty; 2) shaping is prone to cause the angle of collapsing, edge; 3) required work step quantity and number of molds are more, and efficient is low.
Like publication number is that the one Chinese patent application " gear precision plastic forming process and finishing die thereof " of CN1367051A belongs to this type.
In a word, there are many deficiencies in existing gear teeth Precision Forming Technology, mainly show as following some:
1) grand full ridge approach gear teeth corner filling difficulty, workpiece demoulding difficulty.
2) floating cavity die shaping, closing mould forging, the shunting die needed complex structure that is shaped, the equipment needed thereby action is complicated.
3) the wheel toothed portion of shunting shaping needs the same die cavity of twice entering, and has certain waste of material.
4) standard-sized sheet groove approach is difficult to be applicable to the gear forming that radial dimension is big, modulus is bigger.
5) grand full ridge approach and the required plastic force of standard-sized sheet groove approach are big, and the mould service condition is abominable.
6) with cylindrical blank directly " pushing away " can form at tooth top and conflux foldingly, the angle of collapsing, initiating terminal edge is serious.
7) " open Long Geng-expansions groove " approach first step weakening strength of concave mould, subsequent step are prone to cause the angle of collapsing, edge, and required work step and number of molds is many, efficient is low.
Prior art exists the reason of many deficiencies to mainly contain: 1) shaping approach is unreasonable; 2) there are not preform or preform to owe reasonable; 3) whole shaping die shape is unreasonable.
Summary of the invention
The objective of the invention is the deficiency that exists to prior art, propose to realize directly/precision form of the angular gear gear teeth through " increase footpath half Long Geng-split groove " approach and corresponding mould.
The present invention is (is example with the straight spur gear) of realizing through the following technical scheme of being made up of two steps.
The first step is that two ends radial dimension and end surface shape there are differences with cylinder blank (1) closed die forging, and cylinder is the performing member (2) of " increasing footpath half Long Geng " state; Second step, performing member (2) is passed each teeth groove corresponding position be provided with the whole shaping die (12) of splitting sword, wheel rim is split squeezed distortion, each bottom land is deepened, each ridge jacking is high, obtains the complete gear teeth of flank profil.
(1) as the preform step, the rational division of work that the shaped design of performing member (2) has been considered in advance, has been shaped eventually has following characteristic with closed die forging in the present invention.
One of characteristic is for remedying whole shaping The initial segment outside circle undersize, on meridian plane (referring to accompanying drawing 4), to get big end (6) tip diameter D
1Be by (D-2b) ~ D (referring to I side, the accompanying drawing 5 of accompanying drawing 4) that D is whole formed tooth outside diameter circle, b is whole formed tooth bottom land width.Big end (6) tip diameter D
1With small end (7) tip diameter D
yBetween with the angle of inclination
γ 1Transition is got
γ 1It is 2 ° ~ 10 °.Simultaneously, big end (6) root diameter D
2With small end (7) root diameter D
0Between (being blank diameter) (referring to II side, accompanying drawing 5 of accompanying drawing 4) with
γ 2Transition is got
γ 2It is 1 ° ~ 7 °.This shape facilitates for performing member (2) depanning just.
Two of characteristic is, for remedying the angle of collapsing, whole shaping initiating terminal edge, on meridian plane (referring to accompanying drawing 4), increased big end (6) edge axial dimension (referring to the I side of accompanying drawing 4) from interior to outer gradual change.Edge extent is meant D
1To the annular region between the D-2 (Δ R+b), D
1Be big end (6) tip diameter, (D is whole formed tooth outside diameter circle to D-2 (Δ R+b) for whole shaping stage non-deforming region diameter; Δ R is whole shaping tooth depth; B is whole formed tooth groove bottom width, referring to accompanying drawing 5).Get tooth axially the amount of increasing Δ H be (0.4 ~ 0.8) Δ R; At big end (6), with curved surface f transition, curved surface f is the conical surface or for being that benchmark is the curved surface of 0 ~ Δ H/3 to the outer lug amplitude with the conical surface between non-deforming region and the tooth top.This shape is convenient to just guarantee that the big end of performing member (2) (6) filling is good.
Three of characteristic is; On axis projection figure (referring to accompanying drawing 5); The area that performing member small end axis projection profile (9) is surrounded equals the area that flank profil (8) is surrounded; But performing member small end axis projection profile (9) concavo-convex (or bending) degree is slowed down, and is a kind of a kind of " increasing footpath half Long Geng " shape between average diameter profile (10) and flank profil (8).So-called " increasing footpath half Long Geng " be meant the complete grand ridge approach two-step method in the relative background technology original be " Ban Longgeng " of benchmark with the root circle, the preform root diameter (is blank diameter D
0) obviously increase.Concavo-convex amplitude size Δ R
ySpan be (0.25 ~ 0.75) Δ R, Δ R is whole shaping tooth depth.Performing member small end axis projection profile (9) is a SPL, or is arc transition, and concavo-convex variation should make relative flank profil (8) teeth groove excess area s
2Equal relative flank profil (8) tooth top and lack area s
1This shape has obviously shortened metal at the Radial Flow stroke in preform stage, both can reduce plastic force, can guarantee that again the periphery of performing member is filled good.What is more important can be avoided confluxing folding with the tooth top that directly " pushing away " shaping of cylindrical blank (big modulus) gear teeth exist.
Four of characteristic is; Big end (6) axial projective area is greater than the required area that is shaped eventually; Thereby increased the performing member volume, in whole forming process, these unnecessary volumes that are distributed in big end margin can progressively be replaced to other end transmission; Finally become waste material (14), do not increase the volume of whole drip molding (gear) (13).This unnecessary volume has been brought into play the technological compensa tion effect of similar open die forging, impressing forging overlap just, adapts to stock volume fluctuation, die wear, adds the situation that must occur in the actual production such as thermal losses, for stable production in enormous quantities the in enormous quantities provides guarantee.
Performing member main body axial dimension H
1Equal whole drip molding flange height (referring to accompanying drawing 4, accompanying drawing 7).
Possess the performing member of this given shape, closed die forging is full of easily, and required deformation force is little, and the demoulding is easy.Simultaneously, for being shaped eventually the technological compensa tion volume is provided.
The working portion of preform punch (3) is the positive frictional fit of center projections shape and preform die (4), can guarantee that end (6) filling is good greatly in the closed die forging process.
The used mould structure of preform designs identical with general closed die forging.For improving bearing capacity, die must adopt combining structure, and promptly wale with shrink ring the periphery.
(2) the present invention will push away as whole forming step.Whole shaping die (12) is called clink with the teeth groove corresponding position, and quantity equates with tooth number.Whole shaping die (12) has following characteristic.
One of characteristic is; Each clink head is a wedgelike; Have one to split sword (16) and two working faces (17), split sword (16) for every and formed by two working faces (17) intersection, working face can be plane or the similar fairshaped dimpling curved surface that is easier to make.Need transition face (18) (referring to accompanying drawing 8, accompanying drawing 10) between the adjacent clink, concentrate to avoid stress, rounding promptly obtains transition face (18) between two working faces in opposite directions.
Two of characteristic is, the normal of working face (17) with respect to axially, radially, three directions in tangential are all inclined, the working face angle
α 0Scope is 30 ° ~ 100 ° (referring to accompanying drawings 9), splits cutting edge inclination
βScope is 20 ° ~ 75 ° (referring to accompanying drawings 7).
Three of characteristic is, it is the work zone of h that the clink head has width, and h gets 0.5 ~ 8.0mm (referring to accompanying drawing 7, accompanying drawing 10).
The clink of the interior this structure of whole shaping die had both helped metal and had flowed to predetermined direction, had reduced plastic force again.
The axis projection profile of whole shaping die (12) is exactly the axis projection profile (working position is referring to accompanying drawing 8) of gear.For improving bearing capacity, die must adopt combining structure, and promptly wale with shrink ring the periphery.
The axis projection profile of whole forming terrace die (11) also is the axis projection profile of gear, but circumferentially need slightly reduce, make and whole shaping die (12) between the gap, 0.1 ~ 0.5mm is got in the gap; Whether meridian surface profile has spoke-wheel hub to decide with gear.In the whole forming process, whole forming terrace die (11) mainly plays the power transmission effect.
Whole shaping dies is similar with conventional open die forging, impressing forging edger to a great extent, and whole forming terrace die (11) is almost the same with the side cut punch.
With respect to the preform orientation, whole shaping must be inverted performing member (2), and promptly big end (6) is placed on the whole shaping die (12) down; Whole forming terrace die (11) is descending, promotes performing member (2) and passes whole shaping die (12).With regard to each teeth groove, this step is split and is squeezed distortion, can abbreviate " splitting groove " as.
" splitting groove " of the present invention is meant that the tip clink splits the teeth groove position into performing member (2) vertically; Its deformation process is at the shaping initial stage, to split sword (16) (referring to accompanying drawing 8, accompanying drawing 9, accompanying drawing 10) and at first the initiating terminal gullet base is split branch; Then tilt and rubbing action because of working face (17); Initiating terminal (6) is reverted to plane (being similar to), because of working face (17) comprehensive engagement blank not as yet, so the tooth top protuberance is not obvious; In this stage,,, can near at the bottom of the teeth groove, form highly little convexity (15) (referring to accompanying drawing 7 and accompanying drawing 13) because of the internal stress effect because whole shaping initiating terminal (the big end of former preform) (6) is a Free Surface.
Thereafter, progressively get into the stable state shaping stage, working face (17) forces relative flank profil (8) teeth groove excess area s
2Shift (v in referring to accompanying drawing 5 to tooth root
2), tooth root centripetal direction resistance is very big, arranged by law of minimum resistance, orders about the tooth top generation centrifugal direction motion of half Long Geng, lacks area s to relative flank profil (8) tooth top
1Shift (referring to v in the accompanying drawing 5
1), realize that tooth top increases.See that from the angle of groove the bottom portion of groove metal receives the effect of tangential component and to groove two side flow, groove is deepened; The angle of (gear teeth) is seen from the ridge, and metal receives the effect of both sides tangential component and swells, and obtains the complete gear teeth of flank profil.Metal generation continuous and local distortion in this process.
Because of working face (17) tilts and rubbing action, in " splitting groove " process, on the one hand, inhomogeneous displacement can take place in metal vertically, and promptly replacement can take place to transmit the unnecessary volume of four of the performing member characteristic said big end margins.Thereby the big end radial dimension of performing member increases in given range could guarantee the whole forming effect of initiating terminal (6).On the other hand, the small quantity of material accumulation can appear in clink the place ahead.This displacement and accumulation can remedy closed die forging small end corner again just and owe the deficiency that is full of easily.
Be shaped the later stage, generally having the accumulation of a small amount of the place ahead becomes waste material (14), under the shear action of whole forming terrace die (11) and whole shaping die (12), separates with whole drip molding (gear) (13).Distortion finishes, and whole drip molding (gear) (13) has left whole shaping die (12).In whole shaping end (former preform small end) (7), generally can be along the residual burr of flank profil (8) (19) (referring to accompanying drawing 14).
As for the component shaping temperature, mainly press mould strength and plastic force the size and decide.Under existence conditions, the generally suitable hot or warm attitude of steel spare is shaped.
Workpiece accuracy is by the mould accuracy of manufacture and the decision of forming temperature amplitude of variation.
In the production process, the flowing material with cooling and lubrication can be suitably smeared at the mold work position.
The present invention can be used for helical gear (helix angle at reference cylinder is 8 ° ~ 20 °) precision form (referring to accompanying drawing 15 and accompanying drawing 16).When die and punch move to axial, add getting final product around axis rotation accordingly.
Beneficial effect of the present invention:
With regard to preform, preform die (4) die cavity sidewall concavo-convex (or bending) degree is more slow, and preform punch (3) middle part is high, peripheral low, and metal was filled in mould easily when this structure made closed die forging, and required plastic force is less; Simultaneously, preform die (4) die cavity sidewall tilts with respect to the direction of motion of preform punch (3), is convenient to performing member (2) demoulding.Requiredly eject action and on general forging equipment (like punching machine, fly press, forging hammer etc.), all realize easily.
Just eventually be shaped, whole shaping die (12) is gone up to have adopted with gear teeth corresponding position and is split sword (16) and inclined cut (17), and it is mobile to predetermined direction both to have helped metal, has reduced plastic force again.The distortion that is shaped eventually mainly occurs in apart from gullet base suitable with gullet base width b approximately shallow-layer and gear teeth zone, and for continuous and local is shaped, is not integral-filled shaping, and required plastic force is less.Radial load when the shaping of the gear teeth-teeth groove need not be shaped by spoke or wheel bore.This provides with regard to the precision form for big modulus, the more number of teeth (tip diameter is bigger) gear maybe.Whole shaping dies is simple in structure, is equivalent to the edger of conventional open die forging, impressing forging to a certain extent, uses conventional equipment (like punching machine etc.) to get final product.Because it is little to bear deformation force, the mould service condition is better, and the life-span is long.Whole drip molding (gear) (13) is accomplished distortion and is promptly left mould, does not have release problems.
The present invention has solved the gear teeth that the conventional gears precision form exists and has filled and owe full under the prerequisite that scrap piece loss is arranged slightly, demoulding difficulty, and mould structure complicacy and service condition is abominable requires a series of problems such as complicacy to device motion.And this waste material (unnecessary volume) has been brought into play the technological compensa tion effect of similar open die forging, impressing forging overlap just, can adapt to stock volume fluctuation, die wear, add the situation that must occur in the actual production such as thermal losses, for stable production in enormous quantities the in enormous quantities provides guarantee.The so-called amount of waste material that has scrap piece loss to be meant the method loss that the present invention proposes slightly only be about conventional open die forging, impressing forging overlap 1/3 or still less, very little to economic influence.
In a word, the present invention requires low to process conditions, wide adaptability.
It is contemplated that the manufacturing process that the present invention is proposed and mould is used for continuous upsetter or organize production line can obtain very high production efficiency.
Description of drawings
Accompanying drawing 1 is the shape of blank 1.Wherein, D
0Be blank diameter; H
0Be the blank height.
Accompanying drawing 2 is preform process mould closes state principal section figure.Wherein, 1 is blank (profile); 2 is performing member; 3 is the preform punch; 4 is the preform die; 5 is kicker.
Accompanying drawing 3 is the vertical view (working portion partial view) of preform die 4.Wherein, 1 is blank (profile); 4 is the preform die.
Accompanying drawing 4 is the meridian plane figure of performing member 2.Wherein, I was the meridian plane of tooth top; II was the meridian plane at the bottom of the teeth groove.1 is blank (profile); 2 is performing member; 6 are big end (also being whole shaping initiating terminal); 7 are small end (also being whole shaping end); D
1Be big end tooth outside diameter circle; D
2Be big end tooth root diameter; (D is whole shaping tooth top diameter to D-2 (Δ R+b) for whole shaping stage non-deforming region diameter; Δ R is whole shaping tooth depth; B is whole formed tooth groove bottom width); D
yBe the small end tip diameter; D
0Be small end root diameter (also being blank diameter); H
1Be performing member main body axial dimension (equaling whole shaping flange height); Δ H is the axial dimension that tooth increases; F is the fillet surface between the axial dimension Δ H that increases of whole shaping stage non-deforming region end face and tooth;
γ 1Be big end tooth outside diameter circle D
1With small end tip diameter D
yBetween the transition oblique angle;
γ 2Be big end tooth root diameter D
2With small end root diameter D
0Transition oblique angle between (also being blank diameter); H
0Be the blank height.The partial enlarged drawing of B-B section is accompanying drawing 5.
Accompanying drawing 5 is the cross-sectional view (amplify the part of B-B section in the accompanying drawing 4) of performing member 2 small ends.Wherein, 8 is flank profil; 9 is performing member small end axis projection profile; 10 is the average diameter profile; D is whole formed tooth outside diameter circle; Δ R is whole shaping tooth depth; B is whole formed tooth groove bottom width; D
0Be blank diameter (also being performing member small end root diameter); Δ R
yFor " increase footpath half Long Geng " highly; D
yBe performing member small end tip diameter; s
1The area that lacks for relative flank profil 8 tooth tops; s
2Be the relative unnecessary area of flank profil 8 teeth groove; v
1For preform tooth top metal to whole shaping tooth top shift direction; v
2For preform teeth groove metal to whole shaping tooth root shift direction.
Accompanying drawing 6 is preform mould three-dimensional modeling figure.Wherein, 3 is the preform punch; 4 is the preform die; 5 is kicker.
Accompanying drawing 7 is whole forming process and mould principal section figure thereof.Wherein, the left side is an initial state, and the right side is a done state; 11 is whole forming terrace die; 2 are performing member (being inverted); 7 are whole shaping end (also being the preform small end); 12 is whole shaping die; 13 is whole drip molding (gear); 14 is waste material; 15 is protruding;
βThe cutting edge inclination of splitting for the tip clink; H is a clink head work zone width; H
1Be whole drip molding flange height (equaling performing member main body axial dimension).K is accompanying drawing 9 to (part) view.
Accompanying drawing 8 is the vertical view (working portion partial view) of whole shaping die 12.Wherein, 16 for splitting sword (quantity equals the number of teeth of gear); 17 is working face, and each clink has two working faces; 18 is the transition face between the working face (or adjacent clink) in opposite directions.
Accompanying drawing 9 is that the K of accompanying drawing 7 is to (part) view.Wherein,
α 0Working face angle for the tip clink.
Accompanying drawing 10 is the three-dimensional modeling figure of 12 two clinks of whole shaping die.Wherein, 16 for splitting sword; 17 is working face; 18 is the transition face between the adjacent clink; H is a clink head work zone width.
Accompanying drawing 11 is the photo of performing member 2, and material is that technical pure is plumbous.6 are big end (also being whole shaping initiating terminal), f be whole shaping stage non-deforming region with the axial dimension Δ H of tooth increase between fillet surface.
Accompanying drawing 12 is the photo of waste material 14, and material is that technical pure is plumbous.
Accompanying drawing 13 is a kind of visual angle photo of whole drip molding (gear) 13 (material is that technical pure is plumbous).6 for whole shaping initiating terminal (also being the big end of preform), is the end face that leaves die earlier, and 15 be convexity, be positioned at the bottom of the teeth groove near.
Accompanying drawing 14 is the another kind of visual angle photo of whole drip molding (gear) 13 (material is that technical pure is plumbous).7 for whole shaping end (also being the preform small end), leaves the end face of die after being, 19 be burr, along flank profil 8 distributions.
Accompanying drawing 15 is the design sketch by certain moment in the whole shaping numerical simulation process of the inventive method shaping helical gears (tooth number Z=12, modulus m=4, flange height are 30mm, helix angle at reference cylinder is 12 °).
Accompanying drawing 16 is for accomplishing design sketch by the whole shaping numerical simulation of the inventive method shaping helical gears (tooth number Z=12, modulus m=4, flange height are 30mm, helix angle at reference cylinder is 12 °).
The specific embodiment
Gear precision finishing die of the present invention has closed die forging preform mould, pushed away two kinds of whole shaping dies.
(1) preform mould embodiment sees accompanying drawing 2, accompanying drawing 3, accompanying drawing 6, and the preform working portion of die is made up of preform die 4, preform punch 3, kicker 5.Preform matrix cavity side wall profile is " increasing footpath half Long Geng " shape, and axis projection figure and meridian plane size are to improve bearing capacity referring to accompanying drawing 3, accompanying drawing 4, accompanying drawing 5, accompanying drawing 6, and die must adopt combining structure, and promptly wale with shrink ring the periphery; Preform punch 3 working end meridian plane shapes are pressed performing member 2 big end shape manufacturings, and axis projection is also pressed performing member 2 and made; Kicker 5 axis projection profiles are pressed performing member small end axis projection profile 9 and are made.
(2) whole shaping dies embodiment sees accompanying drawing 7, accompanying drawing 8, accompanying drawing 9, accompanying drawing 10, and whole shaping dies working portion is made up of with whole forming terrace die 11 whole shaping die 12.Whole shaping matrix cavity axis projection figure is a flank profil 8, and the clink that the upper end has quantity to equate with the number of teeth, clink head are split sword 16 and working face 17, and working face is the plane, the working face angle
α 0Get 60 °, split cutting edge inclination
βGet 60 °, work zone width h gets 3mm.For improving bearing capacity, die must adopt combining structure, and promptly peripheral employing shrink ring is waled.Whole forming terrace die 11 axis projection profiles are made by flank profil 8, but circumferentially slightly reduce, and 0.2 mm is got in the gap between the whole shaping die 12; With the workpiece contact jaw face of making even.
Mold materials and heat treatment requirements are referring to the relevant handbook of this specialty.
Precision form process with certain straight spur gear (tooth number Z=12, modulus m=4, flange height are 30mm) is an example, sets forth the practical implementation step that the present invention is used for gear teeth precision form.
1) the blank specification is selected: blank diameter is greater than whole formed tooth root diameter; But should be slightly less than the preform root diameter, be advisable, so that accurately locate can put into preform die thorax after the blank heating; If blank diameter is less than normal, should increase (enclosed) jumping-up work step.
2) blanking: billet size (referring to accompanying drawing 1) by volume principle of invariance is confirmed, notes increasing scrap piece loss and adding thermal losses.
3) blank heating: on induction coil or other firing equipment, blank heating is arrived forging temperature.
4) closed die forging preform (referring to accompanying drawing 2, accompanying drawing 3, accompanying drawing 6): before the work, need mould is carried out reasonable preheating, then; The blank that has heated 1 is placed in the impression of preform die 4, preform punch 3 presses down, and blank deforms; Axial height reduces, and radially inhomogeneous increase becomes " increasing footpath half Long Geng " performing member 2 (referring to accompanying drawing 4, accompanying drawing 5, accompanying drawing 11); After preform punch 3 was up, kicker 5 ejected performing member 2.
5) pushed away shaping (referring to accompanying drawing 7, accompanying drawing 8, accompanying drawing 9, accompanying drawing 10) eventually: (take advantage of waste heat with hot; If lower the temperature; Must additional heat may to forging temperature) the performing member 2 inversions (orientation during with respect to preform; Promptly big end 6 is down) on whole shaping die 12, and note guaranteeing axiality; Whole forming terrace die 11 is descending, promotes performing member 2 with respect to whole shaping die 12 motions, respectively splits sword 16 and at first each gullet base is split branch, and working face 17 forces the unnecessary area s of relative flank profil 8 teeth groove then
2Shift (v in referring to accompanying drawing 5 to tooth root
2), tooth root centripetal direction resistance is very big, arranged by law of minimum resistance, orders about the tooth top generation centrifugal direction motion of half Long Geng, the area s that lacks to relative flank profil 8 tooth tops
1Shift (referring to v in the accompanying drawing 5
1), realize that tooth top increases.Along with whole forming terrace die 11 is descending, the distortion of workpiece generation continuous and local, being shaped eventually is able to progressively accomplish.Except near at the bottom of the teeth groove of whole shaping initiating terminal 6, forming the highly little convexity 15, because of working face 17 inclinations and rubbing action, inhomogeneous displacement can take place in metal vertically, and clink the place ahead small quantity of material can occur and pile up.Stage finally; Whole forming terrace die 11 promotes whole drip molding (gear) 13 and passes whole shaping die 12, and under the shear action of whole forming terrace die 11 and whole shaping die 12, waste material 14 separates with whole drip molding (gear) 13; Whole drip molding (gear) 13 falls, and leaves whole shaping die 12; Waste material 14 is stayed on the whole shaping die 12; Whole forming terrace die 11 is up, takes out waste material 14.If waste material 14 hoops then should adopt certain device for discharging on whole forming terrace die 11.
Need to prove that epimere is described to be the situation of " splitting groove " middle and later periods (stead deformation).Because of working face 17 inclinations and rubbing action; In the process of " splitting groove ", inhomogeneous displacement can take place in metal vertically, and promptly replacement can take place to transmit the unnecessary volume of the big end margin of performing member; Thereby the big end radial dimension of performing member increases in given range could guarantee the whole forming effect of initiating terminal.
In the production process, the flowing material with cooling and lubrication can be suitably smeared at the mold work position.
What more than describe is an operation cycle, accomplishes the precision form of a gear.
Subsequent handling as forging cooling, heat treatment, removing surface, deburring etc. with the forging production process similar.
Claims (1)
1. straight/helical teeth cylindricality gear accurate forming method, it is characterized in that being realized by two steps: the first step is performing member (2) with cylinder blank (1) closed die forging; Second step by holding the order to small end that performing member (2) is passed whole shaping die (12) greatly, split wheel rim and squeezes distortion, and each bottom land is deepened, each ridge jacking is high, obtains the complete gear teeth of flank profil;
The preform mould is pressed performing member (2) shape manufacturing, and described performing member (2) has following structure:
On the meridian plane of performing member (2), get big end (6) tip diameter D
1Be (D-2b) ~ D, D is whole formed tooth outside diameter circle, and b is whole formed tooth groove bottom width; Big end (6) tip diameter D
1With small end (7) tip diameter D
yBetween with the angle of inclination
γ 1Transition is got
γ 1It is 2 ° ~ 10 °; Simultaneously, big end (6) root diameter D
2With small end (7) root diameter D
0Between with
γ 2Transition is got
γ 2It is 1 ° ~ 7 °;
On the meridian plane of performing member (2), increase big end (6) edge axial dimension from interior to outer gradual change, described edge is meant D
1To the annular region between the D-2 (Δ R+b), D
1Be big end (6) tip diameter, D-2 (Δ R+b) is whole shaping stage non-deforming region diameter, and wherein, D is whole formed tooth outside diameter circle, and Δ R is whole shaping tooth depth, and b is whole formed tooth groove bottom width; And get tooth axially the amount of increasing Δ H be (0.4 ~ 0.8) Δ R; With curved surface f transition, curved surface f is the conical surface or for being that benchmark is the curved surface of 0 ~ Δ H/3 to the outer lug amplitude with the conical surface between big end (6) whole shaping stage non-deforming region and tooth top;
On axis projection figure, the area that performing member (2) small end axis projection profile (9) is surrounded equals the area that flank profil (8) is surrounded; The concavo-convex amplitude size of performing member (2) small end axis projection profile (9) Δ R
ySpan be (0.25 ~ 0.75) Δ R, Δ R is whole shaping tooth depth; Performing member (2) small end axis projection profile (9) is SPL or is arc transition, and makes relative flank profil (8) teeth groove excess area s
2Equal relative flank profil (8) tooth top and lack area s
1
Big end (6) axial projective area is greater than the required area that is shaped eventually;
Performing member (2) main body axial dimension H
1Equal whole drip molding flange height;
Described whole shaping die (12) has following structure:
Whole shaping die (12) equates with tooth number with the quantity of teeth groove corresponding position clink;
Each clink head is a wedgelike, has one to split sword (16) and two working faces (17), splits sword (16) for every and is formed by two working faces (17) intersection, and working face is plane or dimpling curved surface;
The normal of working face (17) with respect to axially, radially, three directions in tangential are all inclined, the working face angle
α 0Scope is 30 ° ~ 100 °, splits cutting edge inclination
βScope is 20 ° ~ 75 °;
It is the work zone of h that the clink head has width, and h gets 0.5 ~ 8.0mm;
0.1 ~ 0.5mm is got in gap between whole shaping die (12) and the whole forming terrace die (11).
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| CN201210239825.XA CN102764847B (en) | 2012-07-12 | 2012-07-12 | Precision forming method of straight/helical tooth cylindrical gear |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104772611A (en) * | 2014-01-15 | 2015-07-15 | 施瓦姆自动化技术有限公司 | Forging manufacturing method of gear with teeth |
| CN105436390A (en) * | 2015-11-03 | 2016-03-30 | 南昌大学 | Precision forming method for straight/helical tooth cylinder gear with corners easy to fill and die |
| CN106424523A (en) * | 2015-07-23 | 2017-02-22 | 德西福格成型技术有限公司 | Gearwheel having an axial undercut |
| CN110102697A (en) * | 2018-02-01 | 2019-08-09 | 天津职业技术师范大学 | A kind of gear preparation facilities |
| CN111842762A (en) * | 2020-07-15 | 2020-10-30 | 宁国市华成金研科技有限公司 | Precision casting hot-pressing die and processing method thereof |
| CN112058936A (en) * | 2019-06-10 | 2020-12-11 | 上海汽车变速器有限公司 | Cold extrusion molding process of bevel gear |
| CN112756528A (en) * | 2020-12-18 | 2021-05-07 | 南京工程学院 | Straight gear forming method and device |
| CN112893729A (en) * | 2021-01-15 | 2021-06-04 | 南昌航空大学 | Method for forging branch type forge piece |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104772611A (en) * | 2014-01-15 | 2015-07-15 | 施瓦姆自动化技术有限公司 | Forging manufacturing method of gear with teeth |
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| CN111842762A (en) * | 2020-07-15 | 2020-10-30 | 宁国市华成金研科技有限公司 | Precision casting hot-pressing die and processing method thereof |
| CN112756528A (en) * | 2020-12-18 | 2021-05-07 | 南京工程学院 | Straight gear forming method and device |
| CN112893729A (en) * | 2021-01-15 | 2021-06-04 | 南昌航空大学 | Method for forging branch type forge piece |
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|---|---|
| CN102764847B (en) | 2014-06-18 |
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Application publication date: 20121107 Assignee: Shenzhen Aideli Electromechancial Co., Ltd. Assignor: Nanchang University Contract record no.: 2015440020342 Denomination of invention: Precision forming method of straight/helical tooth cylindrical gear Granted publication date: 20140618 License type: Exclusive License Record date: 20151028 |
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Effective date of registration: 20160119 Address after: 1-3, 518000 floor, seven village water Wai village, big wave street, Longhua New District, Guangdong, Shenzhen, China Patentee after: Shenzhen Aideli Electromechancial Co., Ltd. Address before: 999 No. 330031 Jiangxi province Nanchang Honggutan University Avenue Patentee before: Nanchang University |